U.S. patent application number 12/511194 was filed with the patent office on 2011-02-03 for liner expansion system with a recoverable shoe assembly.
This patent application is currently assigned to ENVENTURE GLOBAL TECHNOLOGY, LLC. Invention is credited to Michael Dennis Bullock, Gregory Marshall Noel.
Application Number | 20110024135 12/511194 |
Document ID | / |
Family ID | 43525914 |
Filed Date | 2011-02-03 |
United States Patent
Application |
20110024135 |
Kind Code |
A1 |
Noel; Gregory Marshall ; et
al. |
February 3, 2011 |
Liner Expansion System with a Recoverable Shoe Assembly
Abstract
A system for expanding a tubular member. In some embodiments,
the system includes an expansion assembly disposed in sealingly
engagement within the tubular member, a shoe assembly releasably
coupled within the tubular member, and a chamber disposed
therebetween. The expansion assembly has a flowbore and a openable
port. The shoe assembly includes a flowbore extending therethrough,
the flowbore in fluid communication with the flowbore of the
expansion assembly and having a valveable passage. When the
valveable passage is closed, the port is adapted to open, whereby
the chamber is fluidicly coupled to the flowbore of the expansion
assembly. When the valveable passage is open, the port remains
closed, whereby the chamber is fluidicly isolated from the flowbore
of the expansion assembly.
Inventors: |
Noel; Gregory Marshall;
(Katy, TX) ; Bullock; Michael Dennis; (Houston,
TX) |
Correspondence
Address: |
Enventure Global Technology, L.L.C.
15995 North Barkers Landing, Suite 350
Houston
TX
77079
US
|
Assignee: |
ENVENTURE GLOBAL TECHNOLOGY,
LLC
Houston
TX
|
Family ID: |
43525914 |
Appl. No.: |
12/511194 |
Filed: |
July 29, 2009 |
Current U.S.
Class: |
166/384 ;
166/217 |
Current CPC
Class: |
E21B 43/105
20130101 |
Class at
Publication: |
166/384 ;
166/217 |
International
Class: |
E21B 19/00 20060101
E21B019/00; E21B 23/00 20060101 E21B023/00 |
Claims
1. A system for expanding a tubular member, the system comprising:
an expansion assembly disposed in sealingly engagement within the
tubular member, the expansion assembly having: a flowbore; and a
openable port; a shoe assembly releasably coupled within the
tubular member, the shoe assembly comprising a flowbore extending
therethrough, the flowbore in fluid communication with the flowbore
of the expansion assembly and having a valveable passage; and a
chamber disposed within the tubular member between the expansion
assembly and the shoe assembly; wherein, when the valveable passage
is closed, the port is adapted to open, whereby the chamber is
fluidicly coupled to the flowbore of the expansion assembly; and
wherein, when the valveable passage is open, the port remains
closed, whereby the chamber is fluidicly isolated from the flowbore
of the expansion assembly.
2. The system of claim 1, wherein the shoe assembly further
comprises a plurality of moveable members, each moveable member
radially extendable to engage the tubular member, whereby rotation
of the shoe assembly relative to the tubular member is prevented
and whereby axial translation of the shoe assembly relative to the
tubular member is prevented in at least a first direction, and
radially retractable to disengage the tubular member.
3. The system of claim 2, wherein the tubular member comprises a
plurality of circumferentially-spaced slots, each slot configured
to receive one moveable member.
4. The system of claim 2, wherein the expansion assembly comprises
a plurality of axially extending splines and wherein the shoe
assembly further comprises a plurality of axially extending splines
configured to interlock with the splines of the expansion assembly,
whereby the expansion assembly is prevented from rotating relative
to the shoe assembly.
5. The system of claim 4, wherein the expansion assembly comprises
an expansion cone and an expansion mandrel inserted therethrough,
wherein the splines of the expansion assembly extend axially from
the expansion mandrel.
6. The system of claim 4, further comprising a tubular support in
fluid communication with a pressurized fluid source and rotatably
coupled to the expansion assembly.
7. The system of claim 1, wherein the shoe assembly comprises: an
outer tubular member having a plurality of radially moveable
members, each moveable member engaging a slot formed in the tubular
member, whereby rotation of the shoe assembly relative to the
tubular member is prevented and whereby axial translation of the
shoe assembly relative to the tubular member is prevented in at
least one direction; and an inner tubular member having a radially
extending shoulder, the inner tubular member translatable within
the outer tubular to engage the outer tubular with the shoulder,
whereby the moveable members disengage the slots.
8. The system of claim 7, wherein an outer diameter of the shoulder
is larger than an inner diameter of the moveable members.
9. The system of claim 1, wherein the shoe assembly comprises: an
outer tubular member having a plurality of radially moveable
members, each moveable member extendable to engage a slot formed in
the tubular member, whereby rotation and axial translation of the
shoe assembly relative to the tubular member is prevented, and
retractable to disengage the slot; and an inner tubular member
having a first portion with a first diameter and a second portion
with a second diameter less than the first diameter, the inner
tubular member translatable within the outer tubular to engage the
moveable members with the first portion, whereby the members extend
to engage the slots, and to axially align the second portion with
the members, whereby the members retract from the slots.
10. The system of claim 9, wherein the inner tubular further
comprises an axially extending shoulder, wherein the second portion
is disposed between the first portion and the shoulder and wherein
the shoulder has an outer diameter exceeding the inner diameter of
the members when retracted.
11. The system of claim 1, wherein the shoe assembly comprises: an
outer tubular member having a plurality of radially moveable
members, each moveable member engaging a slot formed in the tubular
member, whereby rotation of the shoe assembly relative to the
tubular member is prevented and whereby axial translation of the
shoe assembly relative to the tubular member is prevented in at
least one direction; and an inner tubular member translatable
within the outer tubular, the inner tubular member having a neck
adapted for insertion into the expansion assembly, whereby the
flowbore of the shoe assembly is fluidicly coupled to the flowbore
of the expansion assembly.
12. The system of claim 11, wherein the neck comprises at least one
of an external fishing profile and an internal fishing profile.
13. A system for expanding a tubular member, the system comprising:
a tubular launcher having a plurality of circumferentially-spaced
slots extending therethrough; and a shoe assembly sealingly
disposed therein, the shoe assembly having: a flowbore extending
therethrough, the flowbore having a valveable passage; and a
plurality of members, each member radially moveable between an
extended position and a retracted position; wherein, when in the
extended position, each member engages one of the slots, whereby
rotation of the shoe assembly relative to the tubular launcher is
prevented and whereby axial translation of the shoe assembly
relative to the tubular member is prevented in at least a first
direction; and wherein, when in the retracted position, each member
is disengaged from the slots.
14. The system of claim 13, wherein the tubular launcher comprises
an upper launcher and a lower launcher coupled thereto, the lower
launcher having the slots extending therethrough.
15. The system of claim 14, wherein the lower launcher has an inner
diameter smaller than an inner diameter of the upper launcher.
16. The system of claim 13, wherein, when the members engage the
slots, the shoe assembly is prevented from axial translation
relative to the tubular launcher.
17. The system of claim 16, wherein each member is a lug having a
body, wherein the body is extendable into one of the slots and
retractable from the slot, and a head coupled thereto, wherein the
head has cross-sectional area greater than a cross-sectional area
of each slot.
18. The system of claim 17, wherein the lugs are spring-loaded and
biased radially inward.
19. The system of claim 13, wherein each member is an axially
extending collet with a foot that is insertable within and
retractable from each of the slots, the foot having a surface that
slideably engages a surface bounding the slot in which the foot is
inserted.
20. The system of claim 19, wherein each collet is flexible, such
that the collet is bendable in the radial direction to engage its
foot within the slot and to disengage its foot from the slot.
21. A method for expanding a tubular member in a wellbore, the
method comprising: releasably coupling a shoe assembly within the
tubular member; delivering pressurized fluid through a flowbore of
the shoe assembly, the flowbore having a valveable passage; closing
the valveable passage, whereby the pressurized fluid is diverted
into a chamber disposed between the shoe assembly and an expansion
cone; translating the expansion cone relative to the tubular member
under hydraulic pressure, whereby the expansion cone radially
expands the tubular member; disengaging the shoe assembly from the
tubular member; and retrieving the shoe assembly from the
wellbore.
22. The method of claim 21, wherein the releasably coupling
comprises: inserting the shoe assembly within the tubular member;
and radially extending each of a plurality of moveable members
coupled to the shoe assembly into a slot formed in the tubular
member.
23. The method of claim 21, wherein the closing comprises seating a
ball on a ball seat formed within the shoe assembly across the
valveable passage.
24. The method of claim 21, wherein the disengaging comprises:
applying a tension load to the shoe assembly; displacing the shoe
assembly relative to the tubular member; and retracting each of a
plurality of radially extended moveable members from a slot formed
in the tubular member.
25. The method of claim 24, wherein the applying comprises coupling
a wireline to the shoe assembly and pulling on the wireline.
26. The method of claim 24, wherein the retracting comprises:
bending each moveable member radially away from the tubular member;
and slideably engaging a surface on each moveable member over a
surface bounding the slot in which the moveable member is disposed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] The present disclosure relates generally to an apparatus for
expanding tubular members. More particularly, the present
disclosure relates to a recoverable shoe assembly for a liner
expansion system.
[0004] To form a wellbore using some conventional systems and
methods, a drill string initially forms a borehole, and a casing is
then installed at the top portion of the borehole. Next, the drill
string extends the length of the borehole below the casing. An
expandable tubular member, or liner, is then suspended by an
expansion assembly within the casing. The expansion assembly
includes a tubular member supporting an expansion cone. The
expandable liner is then radially expanded by the expansion cone
into engagement with the casing to extend the lining of the
borehole.
[0005] The expandable liner includes a shoe at its lower end and a
launcher assembly disposed therebetween. The shoe has a valveable
passage extending therethrough. The launcher assembly has a lower
portion connected to the shoe, an upper portion connected to the
expandable liner, and a tapered portion extending therebetween. The
inner diameter of the lower portion is greater than that of the
upper portion, enabling the launcher assembly to receive the
expansion cone therein. The expansion cone sealingly engages the
lower portion of the launcher assembly. Thus, a chamber is formed
within the launcher assembly between the expansion cone and the
shoe. The shoe passage, when open or closed, enables or prevents,
respectively, fluid communication between the launcher assembly
chamber and the annulus between the borehole and expandable liner.
The expandable liner is supported by the tubular support member via
engagement between the tapered portion of the launcher assembly and
the expansion cone.
[0006] Prior to expansion of the expandable liner, a ball, or dart,
is delivered via pressurized fluid injected from the surface
through the tubular support member, expansion cone, and launcher
assembly to seat on the shoe passage, thereby closing the passage
and preventing subsequent flow of the pressurized fluid
therethrough. Continued injection of pressurized fluid causes
pressurized fluid to fill the launcher assembly chamber. When the
pressure of fluid contained within the launcher assembly chamber
reaches a sufficient level, the fluid pressure causes the expansion
cone disposed within the launcher assembly to displace upward
within the launcher assembly into the expandable liner. As the
expansion cone travels upward within the liner, engagement between
the cone and the liner causes radial expansion of the liner.
[0007] After the liner has been expanded into engagement with the
casing, the expansion cone is removed from the borehole. To again
extend the length of the borehole below the now-expanded liner, the
shoe coupled to the lower end of the expanded liner must first be
removed. The drill string is inserted within the liner, and the
shoe is drilled out. Once removed, successive expandable tubulars
may be installed and the borehole extended in the same manner until
the wellbore reaches the desired depth.
[0008] As the shoe is drilled out, pieces of it fall into the
borehole. Occasionally, these pieces block the borehole, thereby
preventing further extension of the borehole. Consequently, it
becomes necessary to divert the borehole around the blockage, or
abandon the wellbore and form another. Given the significant cost
associated with both, there is a need for a recoverable shoe that
enables installation of an expandable liner.
SUMMARY OF THE DISCLOSURE
[0009] A system including a recoverable shoe assembly for expanding
a tubular member, or liner, is disclosed. In some embodiments, the
expansion system includes an expansion assembly disposed in
sealingly engagement within the tubular member, a shoe assembly
releasably coupled within the tubular member, and a chamber
disposed therebetween. The expansion assembly has a flowbore and a
openable port. The shoe assembly includes a flowbore extending
therethrough, the flowbore in fluid communication with the flowbore
of the expansion assembly and having a valveable passage. When the
valveable passage is closed, the port is adapted to open, whereby
the chamber is fluidicly coupled to the flowbore of the expansion
assembly. When the valveable passage is open, the port remains
closed, whereby the chamber is fluidicly isolated from the flowbore
of the expansion assembly.
[0010] In other embodiments, the expansion system includes a
tubular launcher having a plurality of circumferentially-spaced
slots extending therethrough and a shoe assembly sealingly disposed
therein. The shoe assembly has a flowbore extending therethrough,
the flowbore having a valveable passage, and a plurality of
members, each member radially moveable between an extended position
and a retracted position. When in the extended position, each
member engages one of the slots, whereby rotation of the shoe
assembly relative to the tubular launcher is prevented and whereby
axial translation of the shoe assembly relative to the tubular
member is prevented in at least a first direction. When in the
retracted position, each member is disengaged from the slots.
[0011] Some methods for expanding a tubular member, or liner, in a
wellbore include releasably coupling a shoe assembly within the
tubular member, delivering pressurized fluid through a flowbore of
the shoe assembly, the flowbore having a valveable passage, closing
the valveable passage, whereby the pressurized fluid is diverted
into a chamber disposed between the shoe assembly and an expansion
cone, translating the expansion cone relative to the tubular member
under hydraulic pressure, whereby the expansion cone radially
expands the tubular member, disengaging the shoe assembly from the
tubular member, and retrieving the shoe assembly from the
wellbore.
[0012] Thus, embodiments described herein comprise a combination of
features and characteristics intended to address various
shortcomings associated with certain prior devices. The various
characteristics described above, as well as other features, will be
readily apparent to those skilled in the art upon reading the
following detailed description of the preferred embodiments, and by
referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a detailed description of the disclosed embodiments,
reference will now be made to the accompanying drawings in
which:
[0014] FIG. 1 is a cross-sectional view of a liner expansion system
including a recoverable shoe assembly in accordance with the
principles disclosed herein;
[0015] FIG. 2 is a cross-sectional view of the expansion cone of
FIG. 1;
[0016] FIG. 3 is a cross-sectional view of the launcher assembly of
FIG. 1;
[0017] FIG. 4 is a schematic, side view of the collet assembly of
FIG. 1;
[0018] FIG. 5 is a schematic side view of the collet assembly
assembled between the expansion cone and the lower launcher of FIG.
1;
[0019] FIG. 6 is a schematic, side view of the guide mandrel of
FIG. 1; and
[0020] FIGS. 7A and 7B are cross-sectional views of a liner
expansion system including another embodiment of a recoverable shoe
assembly coupled to and released from, respectively, an expandable
liner.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS
[0021] The following description is directed to exemplary
embodiments of a liner expansion system including a recoverable
shoe assembly. The embodiments disclosed should not be interpreted,
or otherwise used, as limiting the scope of the disclosure,
including the claims. One skilled in the art will understand that
the following description has broad application, and that the
discussion is meant only to be exemplary of the described
embodiments, and not intended to suggest that the scope of the
disclosure, including the claims, is limited to those
embodiments.
[0022] Certain terms are used throughout the following description
and the claims to refer to particular features or components. As
one skilled in the art will appreciate, different persons may refer
to the same feature or component by different names. This document
does not intend to distinguish between components or features that
differ in name but not function. Moreover, the drawing figures are
not necessarily to scale. Certain features and components described
herein may be shown exaggerated in scale or in somewhat schematic
form, and some details of conventional elements may not be shown in
interest of clarity and conciseness.
[0023] In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. . ." Also, the term "couple" or "couples" is intended to mean
either an indirect or direct connection. Thus, if a first device
couples to a second device, that connection may be through a direct
connection, or through an indirect connection via other devices and
connections. Further, the terms "axial" and "axially" generally
mean along or parallel to a central or longitudinal axis. The terms
"radial" and "radially" generally mean perpendicular to the central
or longitudinal axis, while the terms "azimuth" and "azimuthally"
generally mean perpendicular to both the central or longitudinal
axis and a radial axis normal to the central longitudinal axis. As
used herein, these terms are consistent with their commonly
understood meanings with regard to a cylindrical coordinate
system.
[0024] Referring now to FIG. 1, there is shown a liner expansion
system including a recoverable shoe assembly in accordance with the
principles disclosed herein. Liner expansion system 100 includes an
expansion assembly 105 coupled to a recoverable shoe assembly 110
installed within an expandable tubular member, or liner, 115.
Expansion assembly 105 is hydraulically actuatable to displace
upward within expandable liner 115 relative to shoe assembly 110 to
radially expand liner 115. Shoe assembly 110 enables coupling of a
pressurized fluid source (not shown) to expansion assembly 105,
whereby pressurized fluid is delivered through expansion assembly
105 to a chamber 120 within expandable liner 115. The pressurized
fluid within chamber 120 causes upward displacement of expansion
assembly 105 within expandable liner 115, whereby engagement
between expansion assembly 105 and liner 115 causes radial
expansion of liner 115. Shoe assembly 110 also sealingly engages
the lower end 125 of expandable liner 115 to enable pressurization
of chamber 120.
[0025] Expansion assembly 105 includes an expansion cone 130, an
expansion mandrel 135 inserted therethrough, and a tubular support
member 140 coupled to the upper end 145 of expansion mandrel 135.
Tubular support member 140 has a flowbore 150 extending
therethrough, and, in this embodiment, is coupled to upper end 145
of expansion mandrel 135 via mating threads 155 formed on the inner
and outer surfaces of tubular support member 140 and expansion
mandrel 135, respectively. Flowbore 150 of tubular support member
140 is in fluid communication with, or is fluidicly coupled to, the
pressurized fluid source.
[0026] Expansion mandrel 135 has a flowbore 160 extending
therethrough. When expansion mandrel 135 is coupled to tubular
support member 140, as shown in FIG. 1, flowbore 160 is in fluid
communication with flowbore 150 of tubular support member 140.
Expansion mandrel 135 further includes one or more ports 165
extending therethrough. A rupture or burst disc 170 is seated
within each port 165. Each rupture disc 170 is configured to
prevent fluid flow through port 165 when the pressure of fluid
passing through flowbore 160 is less than a preselected level and
to burst or rupture when the fluid pressure exceeds the preselected
level to allow fluid flow through port 165.
[0027] Referring next to FIG. 2, expansion mandrel 135 further
includes generally radially extending upper and lower surfaces 137,
139, respectively. When expansion assembly 105 is installed within
expandable liner 115, as shown in FIG. 1, expansion cone 130 is
supported by upper surface 137 of expansion mandrel 135. Referring
still to FIG. 2, expansion mandrel 135 further includes a plurality
of circumferentially-spaced splines 230 extending from lower
surface 139. Each spline 230 has a length 235 extending
substantially parallel to a longitudinal centerline 228 of
expansion mandrel 135 and a width 240 that extends substantially
circumferentially or azimuthally relative to centerline 225. Thus,
splines 230 may be referred to as longitudinally or axially
disposed splines. A recess 245 is formed between each pair of
adjacent splines 230. Splines 230 are configured to matingly engage
and interlock with another set of splines extending from
recoverable shoe assembly 110, as will be described.
[0028] Expansion cone 130 has a throughbore 175 configured to
receive expansion mandrel 135 therethrough. Expansion cone 130
further includes an upper portion or neck 180, a lower portion or
base 185, and a tapered portion 190 extending therebetween. Neck
180 of expansion cone 130 has an outer surface 195 defined by a
diameter that enables insertion of neck 180 into an unexpanded
portion 200 (FIG. 1) of liner 115 when expansion assembly 105 is
installed within expandable liner 115, as shown in FIG. 1. Base 185
has an outer surface 205 defined by a diameter that enables radial
expansion of liner 115 to the desired inner diameter and/or wall
thickness. Tapered portion 190 of expansion cone 130 has an outer
surface 210 configured to engage an inner surface 215 (FIG. 1) of
liner 115 to enable expansion cone 130 to radially expand liner
115. In this embodiment, outer surface 210 is substantially linear
and offset relative to a longitudinal centerline 225 of expansion
cone 130 by an angle 220.
[0029] Referring again to FIG. 1, expandable liner 115 includes a
launcher assembly 250 at its lower end 125. In this embodiment,
launcher assembly 250 includes two separate components 260, 265
joined end-to-end by a weld 270. In other embodiments, however,
launcher assembly 250 may be a single-piece component.
[0030] Turning to FIG. 3, launcher assembly 250 includes an upper
launcher 260 and a lower launcher 265. Upper launcher 260 is
tubular, having a lower portion 275, an upper portion 280, and a
tapered portion 285 extending therebetween. Upper portion 280 has
an inner surface 290 defined by a diameter corresponding to the
inner diameter of expandable liner 115 prior to radial expansion.
Lower portion 275 has an inner surface 295 defined by a diameter
that enables expansion cone 130 and shoe assembly 110 to be
inserted therein, as shown in FIG. 1. As previously described,
inner surface 215 of tapered portion 285 engages outer surface 210
of tapered portion 190 of expansion cone 130 during expansion of
liner 115.
[0031] Lower launcher 265 is also tubular, having an outer surface
315 and an inner surface 305 defined by a diameter that enables
expansion cone 130 and shoe assembly 110 to be inserted
therethrough. In this embodiment, the diameter of inner surface 305
is substantially constant along the length of lower launcher 265.
Moreover, in some embodiments, the diameter of inner surface 305 is
slightly less than the inner diameter of lower portion 275 of upper
launcher 260 to promote sealing between lower launcher 265 and shoe
assembly 110.
[0032] Lower launcher 265 further includes a plurality of
circumferentially-spaced slots 310 extending therethrough. Each
slot 310 has a height 335 and a width 340. Further, each slot 310
is bounded by a lower surface 320 and an upper surface 325. In this
embodiment, lower surface 320 is generally planar and extends
normally relative to a longitudinal centerline 345 of launcher
assembly 250. Upper surface 325 is generally planar as well but
offset relative to centerline 345 by an angle 330. The angular
orientation of upper surface 325 is such that height 335 of slot
310 increases through the wall of lower launcher 265 from outer
surface 315 toward inner surface 305.
[0033] Returning to FIG. 1, recoverable shoe assembly 110 includes
a collet assembly 350 and a guide mandrel 355 inserted therein.
When shoe assembly 110 is installed within launcher assembly 250 as
shown, collet assembly 350 is coupled between expansion mandrel 135
of expansion assembly 105 and lower launcher 265 of launcher
assembly 250. Turning to FIG. 4, collet assembly 350 has a
longitudinal centerline 400. The right half of this figure, defined
by centerline 400, is shown in cross-section while the left half of
this figure is not. Collet assembly 350 further includes a seal
mandrel 360 having a generally cylindrical body 362 with an upper
end 365 and a lower end 370. Seal mandrel 360 further includes an
outer surface 375 and an inner surface 377 extending between upper
and lower ends 365, 370. A groove 380 is formed in outer surface
375 to receive a sealing element 385, such as but not limited to an
O-ring. When collet assembly 350 is installed within launcher
assembly 250 of liner expansion system 100, as shown in FIG. 1,
sealing element 385 prevents the leakage of pressurized fluid from
chamber 120 between launcher assembly 250 and collet assembly 350
during radial expansion of liner 115.
[0034] Referring still to FIG. 4, collet assembly 350 further
includes a plurality of circumferentially-spaced splines 390
extending from upper end 365 of seal mandrel 360. Each spline 390
has a length 395 extending substantially parallel to longitudinal
centerline 400 of collet assembly 350 and a width 405 that extends
substantially circumferentially or azimuthally about centerline
400. Thus, splines 390 may also be referred to as longitudinally or
axially disposed splines. A recess 410 is formed between each pair
of adjacent splines 390.
[0035] Splines 390 are configured to matingly engage and interlock
with splines 230 of expansion mandrel 135, as illustrated by FIG.
5. To enable such engagement, length 395 and width 405 of each
spline 390 is selected to enable spline 390 to be received within a
recess 245 between adjacent splines 230 of expansion mandrel 135.
Similarly, length 235 and width 240 of each spline 230 of expansion
mandrel 135 is selected to enable each spline 230 to be received in
a recess 410 between adjacent splines 390 of collet assembly 350.
When the interlocking splines 230, 390 are so engaged, they form an
interlocking mechanism between expansion assembly 105 and shoe
assembly 110 to prevent relative rotation therebetween.
[0036] Referring again to FIG. 4, collet assembly 350 further
includes a plurality of circumferentially-spaced collets 415
extending from lower end 370 of seal mandrel 360. Collets 415 are
configured to enable releasable coupling of collet assembly 350
within launcher assembly 250. Each collet 415 is flexible to enable
limited bending relative to seal mandrel 360. Each collet 415 has
an inner surface 530 defined by a diameter greater than a diameter
of inner surface 377 of seal mandrel 360. Hence, a shoulder 534 is
formed in collet assembly 350 at the transition between seal
mandrel 360 and collets 415. Each collet 415 also has a foot 420
that is insertable within and releasable from a slot 310 (FIG. 3)
of lower launcher 265. Thus, when collet assembly 350 is inserted
within lower launcher 265, each collet 415 can bend radially inward
to enable translation of collet assembly 350 within lower launcher
265 until foot 420 engages, or snaps into, a slot 310, as
illustrated by FIG. 5. Subsequently, each collet 415 can again bend
radially inward to enable disengagement of foot 420 from slot
310.
[0037] Further, each foot 420 of collets 415 has a width 427 that
is slightly less than width 340 (FIG. 3) of the slot 310. Each foot
420 is bounded by a lower surface 425 configured to engage lower
surface 320 (FIG. 3) of slot 310 and an upper surface 430
configured to slidingly engage upper surface 325 (FIG. 3) of slot
310. In this embodiment, lower surface 425, like lower surface 320,
is generally planar and extends normally relative to longitudinal
centerline 400 of collet assembly 350. Upper surface 430, like
upper surface 325 of slot 310, is generally planar as well but
offset relative to centerline 400 by an angle 435 that is
substantially equal to angle 330 of upper surface 325.
[0038] When installed within lower launcher 265, as shown in FIG.
5, collet assembly 350 is prevented from rotating relative to lower
launcher 265 due to engagement between feet 420 of collets 415 with
bounding surfaces of slots 310 of lower launcher 265. Further,
collet assembly 350 is prevented from downward axial translation,
or translation away from expansion mandrel 135, relative to lower
launcher 265 due to engagement between lower surfaces 425 of feet
420 and lower surfaces 320 of slots 310. However, collet assembly
350 may translate in the opposite direction, or axially upward,
relative to lower launcher 265 when sufficient upward tension is
applied to collet assembly 350. This relative movement is enabled
by the sliding engagement between tapered, upper surfaces 430 of
feet 420 and similarly tapered, upper surfaces 325 of slots 310.
Thus, under sufficient upward tension, collet assembly 350
disengages lower launcher 265.
[0039] Referring next to FIG. 6, guide mandrel 355 is tubular in
nature, having a flowbore 440 extending therethrough between an
inlet 445 and an outlet 450. Flowbore 440 includes an upper portion
455, a lower portion 460, and a tapered portion 465 extending
therebetween. Lower portion 460 is bounded by an inner surface 470
of guide mandrel 355 defined by a diameter that is smaller than a
diameter of an inner surface 475 of guide mandrel 355 bounding
upper portion 455. As such, tapered portion 465 forms a ball seat
480.
[0040] Guide mandrel 355 further includes a generally cylindrical
body 485 extending between a fishing neck 490 and a guide nose 495.
Fishing neck 490 is configured to be insertable within flowbore 160
of expansion mandrel 135 of expansion assembly 105 when shoe
assembly 110 is installed within expandable liner 115 in engagement
with expansion assembly 105, as shown in FIG. 1. When so inserted,
flowbore 440 of guide mandrel 355 is in fluid communication with,
or fluidicly coupled to, flowbore 160 of expansion mandrel 135, and
fishing neck 490 sealingly engages the inner surface of expansion
mandrel 135 and collet assembly 350 via sealing elements 492 (FIG.
1). Consequently, pressurized fluid injected from the surface
passes from flowbore 160 of expansion mandrel 135 through flowbore
440 of guide mandrel 355, exiting guide mandrel 355 through outlet
450. To disrupt or prevent fluid flow through guide mandrel 355, a
ball (not shown) may be introduced to the pressurized fluid at the
surface and delivered through upper portion 455 of flowbore 440 to
ball seat 480, whereby fluid flow through guide mandrel 355 is
prevented.
[0041] Guide nose 495 has an upper end 510 connected to body 485, a
lower end 515 wherein outlet 450 of flowbore 440 is disposed, and
an outer surface 520 extending therebetween. The diameter of guide
nose 495 at upper end 510 is greater than that of guide nose 495 at
lower end 515. As such, the diameter of outer surface 520 increases
from lower end 515 of guide nose 495 to upper end 510. Tapering of
outer surface 520 in this manner enables run-in of liner expansion
system 100 into a wellbore containing fluid. In particular, tapered
surface 520 is less resistive to fluid flow than some surfaces
having other shapes or orientations.
[0042] The outer diameter of guide nose 495 at upper end 510 is
greater than that of cylindrical body 485 coupled thereto. Hence, a
shoulder 525 is formed in guide mandrel 355 at the transition
between guide nose 495 and body 485. The outer diameter of guide
nose 495 at shoulder 525 is less than that of inner surfaces 305,
295 of lower and upper launchers 265, 260, respectively. This
enables guide mandrel 355 to be pulled from liner 115 via wireline,
or similar device, as will be described below. Moreover, the outer
diameter of guide nose 495 at shoulder 525 is greater than the
diameter of inner surface 377 (FIG. 4) of seal mandrel 360. As
such, shoulder 525 enables retrieval of collet assembly 350 with
guide mandrel 355 when the latter is pulled from liner 115. When a
tension load is applied to guide mandrel 355 via wireline, or
similar device, guide mandrel 355 initially displaces axially
upward relative to collet assembly 350 until shoulder 525 of guide
mandrel 355 engages shoulder 534 of collet assembly 350. Additional
tension to guide mandrel 355 causes guide mandrel 355 to displace
collet assembly 350 axially upward such that collets 415 disengage
slots 310 of lower launcher 265. Once disengaged, collet assembly
350 is supported by guide mandrel 355 as guide mandrel 355 and
collet assembly 350 are pulled from the wellbore.
[0043] Body 485 of guide mandrel 355 includes lower portion 535
connected to guide nose 495 and an upper portion 540 extending
between lower portion 535 and fishing neck 490. Lower portion 535
has an outer surface 565 defined by a diameter that is smaller than
that of inner surface 530 of collets 415 to provide a clearance 570
(FIG. 1) therebetween. Clearance 570 between collets 415 and guide
mandrel 355 enables collets 415 to bend radially inward to engage
and disengage slots 310 of lower launcher 265, as described
above.
[0044] Upper portion 540 of body 485 has an outer surface 545
defined by a diameter that is slightly less that the diameter of an
inner surface 550 (FIG. 1) of seal mandrel 360. Upper portion 540
includes a groove 555 formed in outer surface 545 to receive a
sealing element 560, such as but not limited to an O-ring. When
guide mandrel 355 is installed within collet assembly 350, as shown
in FIG. 1, sealing element 555 sealing engages inner surface 550 of
seal mandrel 360 to prevent leakage of pressurized fluid from
chamber 120 between guide mandrel 355 and collet assembly 350
during expansion of liner 115.
[0045] In some embodiments, guide mandrel 355 may include either or
both of an external fishing profile 500 and an internal fishing
profile 505, each configured to enable retrieval of guide mandrel
355 and other components coupled thereto, such as collet assembly
350, from a wellbore in which liner expansion system 100 is
installed. In this embodiment, guide mandrel 355 includes both.
External fishing profile 500 is an annular lip formed about the
free end of fishing neck 490. Internal fishing profile 505 is a
shoulder formed along inner surface 455 bounding flowbore 440
proximate inlet 445. To retrieve guide mandrel 355, a wireline, or
similar device, is lowered from the surface into the wellbore to
enclose about lip 500 or to engage shoulder 505. Once connected
thereto, the wireline may then be used to pull guide mandrel 355
and collet assembly 350 from the wellbore.
[0046] Returning to FIG. 1, to assemble liner expansion system 100,
expansion assembly 105 is installed within expandable liner 115.
Expansion mandrel 135 is inserted through bore 175 of expansion
cone 130, and expansion cone 130, with expansion mandrel 135
disposed therein, is inserted through lower launcher 265 into upper
launcher 260 of launcher assembly 250. Next, recoverable shoe
assembly 110 is then coupled to expansion assembly 105 and
expandable liner 115. Guide mandrel 355 is inserted through collet
assembly 350 such that fishing neck 490 of guide mandrel 355
extends into flowbore 160 of expansion mandrel 135 and shoulder 525
of guide mandrel 355 abuts shoulder 534 of collet assembly 350.
Collet assembly 350, with guide mandrel 355 disposed therein, is
inserted into lower launcher 265 to engage collets 415 of collet
assembly 350 within slots 310 of lower launcher 265. Guide mandrel
355 is coupled in position within collet assembly 350 with one or
more shear pins 357 (FIG. 1) extending between guide mandrel 355
and launcher assembly 250. The assembled components are then run-in
to a wellbore to the desired depth.
[0047] Next, tubular support member 140 is coupled to the installed
liner expansion system 100 to provide pressurized fluid to system
100 for expansion of liner 115. Tubular support member 140 is
inserted downhole to couple with expansion mandrel 135. In this
embodiment, tubular support member 140 threadingly engages
expansion mandrel 135 via mating threads 155. As described above,
when collet assembly 350 is installed within lower launcher 265,
the engagement of feet 420 of collets 415 of collet assembly 350
within slots 310 of lower launcher 265 prevents relative rotation
of these components. Further, when collet assembly 350 is coupled
to expansion cone 130 of expansion assembly 105 via interlocking
splines 230, 390, collet assembly 350 cannot rotate relative to
expansion cone 130. Thus, once installed, expansion cone 130 and
expansion mandrel 135 disposed therein are prevented from rotating
relative to liner 115. This enables rotational coupling of tubular
support member 140 to expansion mandrel 135.
[0048] During operation of liner expansion system 100, pressurized
fluid is delivered from the pressurized fluid source at the surface
through flowbore 150 of tubular support member 140, flowbore 160 of
expansion mandrel 135, and flowbore 440 of guide mandrel 355 to
exit system 100 via outlet 450. To initiate radial expansion of
liner 115, a ball (not shown) is introduced to the pressurized
fluid at the surface. The pressurized fluid carries the ball along
the same path to seat on ball seat 480, whereby the flow of
pressurized fluid from guide mandrel 355 through outlet 450 is
interrupted.
[0049] Due to the blockage of fluid flow through flowbore 440 of
guide mandrel 355, the pressure of fluid in flowbore 160 of
expansion mandrel 135 increases until it reaches the preselected
level at which discs 170 rupture. After discs 170 rupture,
pressurized fluid passes from flowbore 160 through ports 165 of
expansion mandrel 135 into chamber 120. When the pressure of fluid
within chamber 120 reaches a sufficient level, pressure acting on
expansion cone 130 causes cone 130 to displace axially upward,
whereby engagement between inner surface 215 of liner 115 and outer
surface 190 of expansion cone 130 causes radial expansion of liner
115. At the same time, collets 415 of collet assembly 350 resist
the axial pressure load of the fluid acting on seal mandrel 360 and
provide support to seal mandrel 360.
[0050] When radial expansion of liner 115 is complete, the flow of
pressurized fluid to system 100 is discontinued, and expansion
assembly 105 is pulled from the wellbore. Next, a wireline, or
similar device, is lowered into the wellbore to engage either
external or internal fishing profiles 500, 505 of guide mandrel
355. A tension load is then applied to guide mandrel 355, causing
severance of shear pins 357 coupled between guide mandrel 355 and
launcher assembly 250. After pins 357 are sheared, guide mandrel
355 displaces axially upward relative to collet assembly 350 until
shoulder 525 of guide mandrel 355 engages shoulder 534 of collet
assembly 350. Continued tension to guide mandrel 355 and therefore
collet assembly 350 causes collets 415 to disengage slots 310 of
lower launcher 265. Once disengaged, guide mandrel 355 and collet
assembly 350 supported thereon are pulled from expanded liner 115.
Thus, shoe assembly 110 is recovered, eliminating the need to drill
out the shoe, as is typically done in conventional liner expansion
systems, and the associated problems.
[0051] In the above-described embodiment, flexible collets 415
enable releasable coupling of recoverable shoe assembly 110 to
launcher assembly 250. One of ordinary skill in the art will
readily appreciate that releasable coupling of these respective
assemblies 250, 110 may be achieved using other types of
mechanisms, or devices. For example, in place of collets, the
recoverable shoe assembly may include a plurality of lugs that are
extendable and retractable to engage and release, respectively, the
launcher assembly.
[0052] FIGS. 7A and 7B depicts a liner expansion system with
another recoverable shoe assembly in accordance with the principles
disclosed herein installed within a lower launcher. As in the liner
expansion system described above, lower launcher 615 is also
tubular, having an outer surface 620 and an inner surface 625
defined by a diameter than enables expansion cone 130 and shoe
assembly 600 to be inserted therethrough. Lower launcher 615
further includes a plurality of circumferentially-spaced slots 630
extending therethrough.
[0053] Recoverable shoe assembly 600 includes a seal mandrel 605,
guide mandrel 355 disposed therein, and a plurality of
circumferentially-spaced lugs 610 that are extendable to engage
slots 630 of lower launcher 615, as shown in FIG. 7A, and
retractable to disengage slots 630, as shown in FIG. 7B. Seal
mandrel 605 has a generally cylindrical body 635 with an upper end
(not shown) and a lower end 640. Although not shown, seal mandrel
605, like seal mandrel 360 described above, includes a plurality of
splines 390 extending from its upper end. Splines 390, as
previously described, are configured to matingly engage and
interlock with splines 230 of expansion mandrel 135. When the
interlocking splines 230, 390 are so engaged, they form an
interlocking mechanism between expansion assembly 105 and shoe
assembly 600 to prevent relative rotation therebetween. Seal
mandrel 605 further includes a plurality of
circumferentially-spaced slots 645 extending therethrough. Each
slot 645 is configured to receive a lug 610, as shown.
[0054] Lugs 610 are actuatable to extend to engage slots 630 of
lower launcher 615, as shown in FIG. 7A, and to retract to
disengage slots 630, as shown in FIG. 7B. In some embodiments, lugs
610 are spring-loaded and biased toward their retracted
orientation. Each lug 610 includes a body 650 and a head 655
coupled thereto. Body 650 is configured to be received within slots
630, 645 of lower launcher and seal mandrel 605, respectively. Head
655 has a cross-section that is larger than that of slot 645,
thereby limiting radial extension of lug 610 within slots 630, 645.
Head 655 engages guide mandrel 355 when guide mandrel 355 is
inserted within seal mandrel 605, as shown. In some embodiments,
one or more of the radial extending surfaces 660 of head 655 are
angled or cropped to enable guide mandrel 355 to be inserted
between lugs 610. The angular nature of surface 660 provides
sliding engagement with upper portion 540 of guide mandrel 355 as
guide mandrel 355 is inserted within lugs 610 and seal mandrel
605.
[0055] During assembly, lugs 610 are installed within seal mandrel
605, and seal mandrel 605 is inserted within lower launcher 615
such that slots 630, 645 align. Guide mandrel 355 is then installed
within seal mandrel 605. As guide mandrel 335 is inserted within
seal mandrel 605, contact between upper portion 540 of guide
mandrel 355 and angled surfaces 660 of lugs 610 causes lugs 610 to
extend into slots 630 of lower launcher 615 and enables guide
mandrel 355 to be received between lugs 610. When lugs 610 engage
slots 630, seal mandrel 605 is prevented from rotating and from
translating axially relative to lower launcher 615. As previously
described, this enables coupling of tubular support member 140
(FIG. 1) to expansion mandrel 135 (FIG. 1).
[0056] When it is desired to remove shoe assembly 600 from lower
launcher 615, for instance, when expansion of a liner coupled to
lower launcher 615 is complete, a wireline, or similar device, is
coupled to guide mandrel 355, and guide mandrel 355 is pulled
upward relative to lower launcher 615, as described above. When
upper portion 540 of guide mandrel 355 translates axially above
lugs 610, lugs 610 retract radially inward toward lower portion 535
of guide mandrel 355 and disengage slots 630 in lower launcher 615,
as shown in FIG. 7B. Once retracted, seal mandrel 605 with lugs 610
supported therein is translatable and rotatable relative to lower
launcher 615. Further upward translation of guide mandrel 355 due
to tension from the wireline causes engagement between lugs 610 and
shoulder 525 of guide mandrel 355. Engagement between shoulder 525
and lugs 610 enables seal mandrel 605 and lugs 610 to be supported
by guide mandrel 355 as shoe assembly 600 is pulled from lower
launcher 615 and the expanded liner coupled thereto.
[0057] While various embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the spirit and teachings herein. The embodiments
herein are exemplary only, and are not limiting. Many variations
and modifications of the apparatus disclosed herein are possible
and within the scope of the invention. Accordingly, the scope of
protection is not limited by the description set out above, but is
only limited by the claims which follow, that scope including all
equivalents of the subject matter of the claims.
* * * * *